Key duplication attachment device for rotary tool with profiled abrasive cutter

ABSTRACT

A key grinding duplicating attachment that includes a base with upright bearing supports juxtaposed which supports a horizontal guide bar transporting control housing assembly. Said assembly movement being slidable on a horizontal axis, swingable upward and downward in contact with top edge of the keys. Base solid mount angled vise support uprights with clamping vises juxtaposed for specimen and blank keys. The said transporting control housing assembly supports a modulate direct output rotary tool high speed high torque motor or an equivalent, profiled abrasive key grinder arbor assembly, a juxtaposed profiled stylus in line. An effortless means to produce usable duplicated keys continually.

BACKGROUND

[0001] Various key cutting machines are known. In accordance with known principals. A specimen key with the essential pattern profile is placed in a vise clamp. A blank key to be contoured patterned is placed in the juxtaposed vise clamp. The specimen key in contact with the stylus. The blank key is contacted with the tooth cutter wheel revolving at approximately 1300 to 1750 rpm when drive belt is not slipping, as tends to be the case in prior art. The carriage vise clamps with affixed keys is shifted laterally, swinging inward and outward causing contoured pattern on the specimen key imparting corresponding pivotal movement. Said cutter cuts a corresponding contour pattern in blank key and then removed from vise clamps. Burrs and imperfections formed while cutting are removed with file or buffing wheel. Wear in the pivot points that support the key clamping vises diminishes the precision required to produce a usable working key.

[0002] The force generated by said cutter cutting against the blank key many times, forces the key with deep cuts, lands and contours to shift or jump out of the highly tightened clamping vise jaws. Many prior art duplication machines contain different configuration clamping vise jaws, vises attempting to overcome said problem. Even with multiple vise jaws, some keys can not be duplicated in said machines because the lands and grooves are lower than the top edge of said vise. Any wear that is in the pivotal points of key vises further contributes to producing unusable duplicated keys.

[0003] Most automotive keys being USA or imports are double sided with lands and grooves on the lip extension of both sides. Most keys contain extended step or steps on each side. Cutting said key requires that the step rests on the top surface of the said jaws. The lip extends between the jaws of said vise, tightened with clamp wing nuts. After one side of said key is cut the lip may become too short to grip securely while cutting. Therefore, the generated force of the said cutter against the blank being duplicated causes the shifting or throwing out of the key blank. Said machines produce a high percentage of unusable duplicated keys. Other disadvantages are the causing by said cutters of unnatural high pitched sounds that cause injury to one's hearing. The cutters are made of heat-treated tool steel. Cutter tooth breakage and dulling is common. Some keys supplied are made of steel. The major manufacturer of said cutters states, in print, that said cutter should not be used to cut steel keys.

[0004] Therefore there is an urgent need for an improved duplication machine system that is cost effective and accurate in the duplication of keys.

[0005] The key duplication attachment device for rotary tool with profiled abrasive cutter invention uses a new principal of operation and powering. It uses high rpms which are contrary to the teaching of prior art. Prior art teaches away from the concepts of the present invention. The invention solves long existing but unsolved problems and limitations of the prior art systems.

[0006] Summary of Prior Art Patents Examined:

[0007] Jan. 27, 1994—U.S. Pat. No. 5,964,554—Wherein the key cutters move both in a linear parallel direction and rotationally with respect to a longitudinal axis thru the key cutter. Not relevant.

[0008] Apr. 14, 1986—U.S. Pat. No. 4,687,389—A machine for coding or duplicating a pattern of bits onto a key blank. Not relevant.

[0009] Sep. 4, 1984—U.S. Pat. No. 4,468,994—A hand controlled punch to punch out bits of keys to code. Not relevant.

[0010] Mar. 23, 1976—U.S. Pat. No. 3,945,298—An automatic working key machine. Not relevant.

[0011] Jul. 29, 1969—U.S. Pat. No. 3,457,832—A key cutter device for duplication of keys having bit portions which are angularly directed with respect to the plane of the body portion of key. Not relevant.

[0012] Sep. 14, 1999—U.S. Pat. No. 5,951,218—An inline rack feed means for effect in a steady key cutting. Not relevant.

[0013] May 17, 1977—U.S. Pat. No. 4,023,464—A key cutting device to simultaneously duplicate two keys. Not relevant.

[0014] Oct. 25, 1988—U.S. Pat. No. 4,780,032—A decoder of manufacturer's code for the purpose of creating a duplicated key. Not relevant.

[0015] Nov. 9, 1993—U.S. Pat. No. 5,259,708—A key cutting machine having manual and automatic modes of operation. Not relevant.

[0016] Nov. 16, 1982—U.S. Pat. No. 4,359,299—A circular cutter having side milling teeth formed on curves. Not relevant.

[0017] Oct. 7, 1980—U.S. Pat. No. 4,226,602—Producing resinoid abrasive wheels. Not relevant.

[0018] Aug. 22, 1978—U.S. Pat. No. 4,107,883—Apparatus for controlling feed mechanisms of grinding and cutting apparatus. Not relevant.

[0019] Jan. 10, 1984—U.S. Pat. No. 4,424,649—An abrasive cutter for cutting metallurgical samples. Not relevant.

SUMMARY

[0020] This invention is an attachment device for rotary tool power sources. Said devise provides a key duplication capability to these types of rotary tool power sources, offering several advantages over existing key duplicating machines, such as portability, smaller size and diminished operating sound level, at a fraction of the cost of prior art machines. Said device also features a slant bed design for ease of operation with cutter and stylus moving over specimen key and the key blank. In prior art machines both cutter and stylus are in a fixed position on the machine with specimen and blank key moving past these fixed points.

Advantages of the Invention Over Prior Art Key Cutting Duplication Machines and Devices

[0021] It is the object of the present invention, key duplication attachment device for rotary tool with profiled abrasive cutter, to provide a key duplication device and method of operating the device that overcomes the limitations and problems of the prior art key duplication machines and devices.

[0022] An object is to provide an easily exchangeable, secured key duplicating attachment to rotary power tools, choice of 110 or 220 volt, air operated motor tool, flexible rotary shaft or battery powered power source. One fixture attachment utilizing an easy change-over, self-contained choice of rotary power tool. Highly portable, self-contained fixture attachment as a means to produce usable keys. Rotary tool is detached when essential key duplication is completed, and said tool may be utilized for other purposes.

[0023] It is a further object of the invention, in utilizing a profiled abrasive cutter, to allow for the operation at higher rpm speeds, so as to increase cutting surface speed from 8,000 to 30,000 rpms without overheating so as to complete duplicating operation in less time. It also offers the ability to grind-cut keys made of steel, brass, iron. No high pitch sounds are emitted that would eventually injure one's hearing. The result being a more accurate duplication of the pattern contour from the specimen key, with cleaner, sharper grinding of the contour pattern, also reducing the force on said key, thereby increasing the stability of the clamping vise. It also eliminates the need for automatic feed cutting and tracing which is featured on prior art duplication machines and devices making said key duplication machines and devices more complicated and cumbersome.

[0024] Still another object of the present invention is to supply an attachment for the rotary tool which is a key grinding, duplicating attachment that includes a base with upright bearing supports juxtaposed supporting, on a horizontal axis, a swingable transporting control housing assembly which supports a rotary power tool or equivalent. The profiled abrasive key cutter arbor assembly is in line with juxtaposed profiled stylus which moves upward and downward and on a horizontal axis contacting the specimen key and blank key as a means to produce a duplicated key.

[0025] Therefore, the invention uses a new principal of powering operation which is contrary to the teaching of prior art. Prior art teaches away from the concepts of the present invention. The invention solves many long existing, but unsolved problems and limitations of prior art machines and systems.

Photograph Legend

[0026]1. Base frame rectangle

[0027]2. Uprights opposed horizontal guide bearing supports

[0028]3. Key clamping vises

[0029]3A. Specimen key

[0030]3B. Blank key

[0031]4. Clamp vise wing nuts

[0032]5. Solid mount angled vise support uprights

[0033]6. Rotary tool power motor.

[0034]6A. Motor control switch

[0035]7. Motor fastening securing nut

[0036]8. Actuating handle—being the rotary tool housing

[0037]9. Horizontal guide-bar transporting control housing

[0038]10. Duplicator profiled stylus

[0039]10A. Stylus adjusting and securing bolt and lock nut

[0040]11. Profiled abrasive key grinder with arbor assembly

[0041]12. Tool chuck

[0042]13. Protection shield

BRIEF DESCRIPTION OF THE BLACK AND WHITE PHOTOGRAPH

[0043] An embodiment of the present invention will now be described by way of example with reference to the accompanying split photograph, top-half (1A) and bottom-half (1B) being the two sections.

[0044] Top-half (1A)

[0045] Being the completed working assembly, photograph section 1A is a front view of embodiment of an improved key duplicating device in accordance with the present invention in which the horizontal guide-bar transporting control housing (9) with fastened rotary tool power motor (6) and motor control switch (6A) and the duplicator profiled stylus (10) and stylus adjusting and securing bolt and lock nut (10A) are shown resting on two uncut key blanks (3B). Edges aligned with the flat sides of the profiled abrasive key grinder with arbor assembly (11) and duplicator profiled stylus respectively. The said keys are held in key clamping vises (3) and are secured with clamp vise wing nuts (4) which are affixed to base frame rectangle (1) which incorporates the uprights opposed horizontal. Guide bearing supports a means to allow for the swinging upward and downward of the horizontal guide bar transporting control housing (9) incorporating the said tool power motor (6) profiled grinder (11) and said profiled stylus (10) with protection shield (12).

[0046] Bottom-half (1B)

[0047] Shown is the disassembled 2 section embodiment of the present invention now being described by way of example with reference to the accompanying bottom half of split photograph (1B).

[0048] Shown top right of bottom half of photograph is base frame rectangle (1) which incorporates uprights opposed horizontal guide bearing supports (2) key clamping vises (3) with vise (3A) for specimen key and (3B) blank key. Clamp vise wing nuts (4) as means to secure said keys (3A) and (3B).

[0049] Shown bottom left of photograph 1B. Horizontal guide bar transporting control housing (9) secured to said housing (9) left side with motor. Fastening nut (7) is rotary tool motor with incorporated motor controls switch (6A). Right side of the housing (9) juxtaposed is duplicator profiled stylus (10) with stylus adjusting and securing bolt and lock nut (10A). Not shown for ease of viewing is protection shield (12).

Making Ready Adjustment for Operation

[0050] The device is first operated by selecting the appropriate rotary tool (6) and the voltage mode of power or a battery powered tool. The rotary tool (6) is fastened to horizontal guide bar transporting control housing mounting hole (9); and extended threaded section extends, front end of the rotary tool (6), inserted in said housing (9) mounting hole. A motor fastening securing nut (7) is turned clockwise to secure the said tool (6) to the said control housing (9). The profiled abrasive key grinder arbor assembly (11) is slipped into the tool chuck (12), lateral alignment controlled by an increased diameter stop on the arbor of the said grinder cutter assembly (11) is tightened securely in tool chuck (12).

[0051] The stylus (6) controls the depth of the grind on the key and is adjusted so as the profiled abrasive grinder (11) is in contact with the aligned key blanks of the same configuration in their respective vises clamps (3A) and (3B). By sliding the control housing (9) containing the operational rotary motor (6) with profiled abrasive grinder (11) running, and adjusted to barely skim the top edge of the key blank.

Operation

[0052] The device is operated by clamping a specimen key in vise clamp (3A) and the key blank in vise (3B) clamp. The vise clamps are affixed to solid mount angle vise support uprights (5) are solid mount to base frame rectangle (1). To align the specimen key with the blank key, the duplicating profiled stylus (10) engages with an extension on the key called key shoulder and/or tip end of the keys whereby positioning the specimen key and the key blank relative to each other, lengthwise. Corresponding exactly with the spacing of the profiled abrasive rotary grinder (6) and stylus (10) against the flat side of the grinder (11) and stylus (10).

[0053] To achieve the corresponding exact said spacing the horizontal guide transporting housing guide bar (9) being supported by the upright opposed bearing support openings (2) allows for movement of said transporting housing (9) to swivel and slide, bringing the profiled abrasive key grinder (11) in conjunction with the flat side of the juxtaposed duplicating profile stylus (10). Key alignment being either shoulder or tip end specimen key. The key blank is brought in contact with the corresponding flat side of the said cutter grinder (11). An actuating handle means (8) being the rotary tool motor housing, controls the movement of the said control housing (9) to slide and swivel upward and downward forcing the said grinder (11) into contact with the blank key and said stylus (10) in contact with specimen key causing the copying of the grooving to be ground thereby following the specimen key with exactness of depth and contour. A usable key is produced. An on and off switch (6A) is incorporated in the body of rotary motor tool (6).

[0054] It will be understood that various modifications could be made to the duplication attachment device without departing from the scope of this invention as set out in appended clams. For instance change profile stylus, type of rotary motor with the type of high-speed rotary essential cutting grinding tool required for the high rpm. The utilizing of additional actuating control handle in conjunction with the tool motor housing.

[0055] Whereby,

[0056] The key cutting attachment device allows for ease of attachment of high speed, high torque tools, rotary power motors of various voltages or battery pack or air motors with abrasive profiled key grinder means, required for the high rpms generated. Simplicity in design of the invention, lower cost, flexibility of power sources, no injurious sounds to hearing, no sharp cutting splinters produced by prior art tooth cutters that might lodge in the skin of the operator. 

1. A horizontal guide transporting housing body which includes through guide bar secured to uprights juxtaposed bearing support means said member having a hole near its upper ends allowing for swinging upward and downward contacting key top surface, also slide on a horizontal axis.
 2. Having a rotary tool power motor and/or high torque high speed power source, having an output shaft, a rotating cutting type cutter attached to an output means.
 3. A horizontal guide transporting housing body to fasten a rotary motor and or rotary motor tool.
 4. A duplicating profiled stylus attached to said transporting housing body means.
 5. A horizontal guide support bar slide incorporated in said transport housing means.
 6. Solid mount vise supports angled to uprights to rectangular base frame.
 7. Clamping vise devices attached to solid mount uprights for clamping keys.
 8. An actuating handle means being the rotary tool motor housing, attached to horizontal guide transporting housing, to force the rotating cutter into contact with blank key and a duplicating profiled stylus, in contact with specimen key. 